Modular transfer units, systems, and methods

ABSTRACT

A modular transfer system with a primary flow system and a diverter system. The primary flow system includes a primary flow belt for conveying an article along a primary flow path from an infeed side of the modular transfer system to a pass-through side of the modular transfer system. The diverter system includes one or more diverter belts for diverting an article from the primary flow path towards a divert side of the modular transfer system. The primary flow belt includes multiple movable components contacting the diverter belt. The movable components can have one or more rotational degrees of freedom.

CROSS REFERENCE

This application claims the priority benefit under at least 35 U.S.C. §119 of U.S. Patent Application No. 62/470,068, filed Mar. 10, 2017; U.S.Patent Application No. 62/470,760, filed Mar. 13, 2017; and U.S. PatentApplication No. 62/479,920, filed Mar. 31, 2017. Each of theaforementioned applications are hereby incorporated by reference hereinin their entirety.

BACKGROUND Field

The present disclosure relates to systems and methods for conveyinggoods from a first location to a second location. More specifically,some aspects of the present disclosure relate to modular conveyorcomponents that can transfer goods to other components of a conveyorsystem.

Description of Certain Related Art

Conveyors can be used in various commercial and manufacturingapplications to transport objects between different processing stationsand locations. A conveyor typically includes a conveyor belt or chainthat is arranged in an endless loop and driven to transport the objectson the belt or chain surface along a generally horizontal path.

SUMMARY OF CERTAIN FEATURES

This disclosure encompasses various embodiments of modular transferunits, systems, and methods. In some embodiments, the embodiments areconfigured to transfer packages from one conveyor belt to another. Insome embodiments, the modular transfer unit (also called a divert unitor a sorter station) allows effective sortation of a wide range ofpackages. Some embodiments can solve the issue of having problemsdiverting problematic packages, such as certain small, soft, and/orunusually shaped packages. A need to be able to convey and divert suchproblematic packages can be beneficial. For example, market changes ine-commerce have led to a need to be able to divert a wider range ofpackage types. A particular need is present for conveying and sorting ofpolybags, which are typically non-rigid bags that articles are placedinto for shipment.

Some embodiments disclosed require no vertical lift (e.g., in thez-direction parallel with a vertical axis) to perform the divert and/orrequire no moving components external to the belt to directly contactthe goods. For example, some embodiments do not require verticalmovement of a component to conduct a sortation procedure. Someembodiments disclosed allow sorting of products without the use of apusher, compressed air, or z-axis direction lift mechanism. Someembodiments include low voltage and/or torque output, which can allowfor safe operating conditions near personnel from moving parts andexcessive noise. Some embodiments run on demand, which can allow forshut down when no product is present to save energy and diminish noise.

Certain embodiments include a plurality of rollers, such as at least onemotorized roller and at least one idler roller, at least one main belt,at least one transfer belt, one or more controls, and one or moresensors (e.g., optical sensors or “photo-eyes”) to arrive at acompletely modular and safe method of diverting a wide range of productswithout the need for vertical lift of z-axis mechanism and without theneed for compressed air. Some variants include sufficiently smallspacing between rollers (e.g., spheres) to allow for very small packagesto be diverted (e.g., spheres are less than or equal to about 1″ apartcenter-to-center). Some implementations make use of 24 VDC motors andcontrols, which can allow for an easy and user friendly installation andcommissioning.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages are described belowwith reference to the drawings, which are intended to illustrateembodiments of modular transfer systems including embodiments of variousconveyor systems which utilize modular transfer systems.

FIG. 1 is a top-down schematic of an embodiment of a modular transferunit.

FIG. 2 is a partial cross-sectional schematic of the modular transferunit of FIG. 1.

FIG. 3 is a perspective view of an embodiment of a modular transferunit.

FIG. 4 is a partial, cut-away view of the modular transfer unit of FIG.3.

FIG. 5 is a top-down schematic of an embodiment of a modular transferunit.

FIG. 6 is a top-down schematic of the modular transfer unit of FIG. 5with different components.

FIG. 7 is a top-down schematic of an embodiment of a conveyor systemwith a modular transfer unit with a package on a component of theconveyor system.

FIG. 8 is a top-down schematic of the conveyor system of FIG. 7, after apackage has been conveyed to the modular transfer unit.

FIG. 9 is a top-down schematic of an embodiment of a conveyor systemwith multiple modular transfer units.

FIG. 10 is a top-down schematic of an embodiment of a conveyor systemwith multiple modular transfer units arranged serially.

FIG. 11 is a flow diagram of an embodiment for transferring a package.

FIG. 12 is a top-down schematic of an embodiment of a multi-zone modulartransfer unit.

FIG. 13 is a top-down schematic of an embodiment of a multi-zone modulartransfer unit.

FIG. 14 is a top-down schematic of an embodiment of a conveyor systemwith a multi-zone modular transfer unit with multiple packages on themulti-zone modular transfer unit.

FIG. 15 is a top-down schematic of conveyor system of FIG. 14 with apackage positioned between zones of the multi-zone modular transferunit.

FIG. 16 is a top-down schematic of an embodiment of a multi-zone modulartransfer unit illustrating simultaneous diversion and rotation of apackage.

FIG. 17 is a front view of an embodiment of a driver.

FIG. 18 is a side view of the driver of FIG. 17.

FIG. 19 is a perspective view of another embodiment of a driver and abelt.

FIG. 20 is a front view of another embodiment of a driver.

FIG. 21 is a side view of the driver of FIG. 20.

FIG. 22 is a partial cross-section view of a schematic divert system.

FIGS. 23A and 23B are perspective and side views of a diverter beltunit.

FIG. 24 is a partial cross-sectional view of a transfer module and twoprimary flow belts.

FIGS. 25A and 25B are perspective and exploded views of a transfermodule and a sensor.

FIG. 26 is a perspective view of a diverter belt with filler elements.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

Certain terminology may be used in the following description for thepurpose of reference only, and thus are not intended to be limiting. Forexample, terms such as “upper”, “lower”, “upward”, “downward”, “above”,“below”, “top”, “bottom”, “left”, and similar terms refer to directionsin the drawings to which reference is made. Such terminology may includethe words specifically mentioned above, derivatives thereof, and wordsof similar import. Similarly, the terms “first”, “second”, and othersuch numerical terms referring to structures neither imply a sequence ororder unless clearly indicated by the context.

The modular transfer units described herein can be utilized in aconveyor system which can have other conveying devices, such as beltedconveyors and/or roller conveyors, which can convey packages as well asreceptacles which can receive the conveyed packages at desiredlocations. The modular transfer units may be self-contained deviceswhich beneficially allow the modular transfer unit to be selectivelyused in or removed from a conveyor system, or moved around a conveyorsystem on an as-needed basis. The modular transfer units may bestand-alone devices (e.g., self-supporting and/or not physically securedto other components of the conveyor system). The modular transfer unitsdescribed herein can have a rectangular shape with four sides. Thisgeometry which may allow the modular transfer unit to be more widelyimplemented in current commercial conveyor systems. However, it is to beunderstood that the modular transfer unit can have different shapes witha different number of sides (e.g., pentagon with five sides, hexagonwith six sides, circular, etc.).

The modular transfer units described herein can receive packages fromother components of a conveyor system. In some embodiments, the modulartransfer unit can allow the package to “pass through” the modulartransfer unit such that the package is allowed to continue along its“primary flow path”. That is, the modular transfer unit conveys thepackage to a component of the conveyor system which is positionedopposite of the component from which the modular transfer unit receivedthe package. This may occur with little to no change in direction forthe package. In some embodiments, the modular transfer unit can divertthe package from this “primary flow path”. That is, the modular transferunit redirects the package to a component of the conveyor system whichis not positioned opposite of the component from which the modulartransfer unit received the package. This may occur with a significantchange in direction for the package. For example, as will be shown inthe embodiments below, this may cause a generally perpendicular (e.g.,about 90 degree) shift in direction for the package; however, it is tobe understood that lower degrees of shift (e.g., less than or equal toabout: 30 degrees, 45 degrees, 60 degrees, 75 degrees, 90 degrees, etc.)are contemplated.

For purposes of this disclosure, the modular transfer units will bedescribed as having a single infeed side, a single pass-through side,and one or more divert sides. This would be applicable in circumstancesin which the modular transfer unit is utilized in a conveyor systemwhich provides packages to the modular transfer unit at a singlelocation. However, it is to be understood that the modular transfer unitcan be utilized in conveyor systems having other configurations andwhich may provide packages to the modular transfer unit at multiplelocations. In such circumstances, the modular transfer unit can havemultiple infeed sides. Moreover, the pass-through sides may be a divertside or vice versa (depending on the specific location at which themodular transfer unit receives a package).

While the present description sets forth specific details of variousembodiments, it will be appreciated that the description is illustrativeonly and should not be construed in any way as limiting. Additionally,although particular embodiments may be disclosed or shown in the contextof conveyor systems which convey packages, it is to be understood thatthe systems described herein can be utilized with any other types ofitems, goods or articles. As such, the terms packages, articles, goods,and items may be used interchangeably. For example, any component,structure, step, method, or material that is illustrated and/ordescribed in one embodiments can be omitted or can be used with orinstead of any component, structure, step, method, or material this isillustrated and/or described in another embodiment.

Example Embodiments of a Modular Transfer Unit

With reference to FIGS. 1 and 2, a schematic of a modular transfer unit100 is illustrated. With reference first to FIG. 1, the modular transferunit 100 can have an infeed side 102 at which the modular transfer unit100 can receive one or more packages from a conveyor system. In someimplementations, the modular transfer unit 100 can be attached tocomponents of a conveyor system which deliver the packages to the infeedside 102 of the modular transfer unit 100. The modular transfer unit 100can allow packages to pass through the modular transfer unit 100 in aprimary flow path (e.g., in a direction along the x-axis). The modulartransfer unit 100 can have a pass-through side 104 at which the modulartransfer unit 100 can discharge packages which are intended to be passedthrough the modular transfer unit 100. In some implementations, themodular transfer unit 100 can be attached to components of a conveyorsystem which receive the packages discharged from the pass-through side104.

The modular transfer unit 100 can redirect or divert packages from theprimary flow path. The modular transfer unit 100 can have a first divertside 106 and/or a second divert side 108 at which the modular transferunit 100 can discharge packages which are intended to be diverted by themodular transfer unit 100. In some implementations, the first divertside 106 and/or the second divert side 108 of the modular transfer unit100 can be attached to components of a conveyor system which receive thepackages which have been diverted from the primary flow path of theconveyor system.

The modular transfer unit 100 can include a first conveyance system 110and a second conveyance system 120. The first conveyance system 110,which can be a primary flow system, can move packages along a directionof the primary flow path (e.g., in a direction along the x-axis). Asshown, the primary flow system 110 can include a primary flow belt 112(also called a main belt). The primary flow belt 112 can extend betweenthe infeed side 102 and the pass-through side 104 of the modulartransfer unit 100. The primary flow system 110 can include a driver 114,such as a motor, which can be directly coupled to the primary flow belt112 or indirectly coupled via one or more intermediate components, suchas gears. The driver 114 can move the primary flow belt 112 in adirection from the infeed side 102 to the pass-through side 104 of themodular transfer unit 100. In some embodiments, the driver 114 can movethe primary flow belt 112 in a direction from the pass-through side 104to the infeed side 102 of the modular transfer unit 100. The driver 114can be reversible or intermediate components between the driver 114 andthe primary flow belt 112 can allow the driver 114 to drive the primaryflow belt 112 in reverse.

In some embodiments, the primary flow belt 112 can be a roller-top belt,such as, the 2253RT belt (available from System Plast S.r.l.). Theprimary flow belt can include any feature or combination of featuresthat are the same, or similar to, those described in U.S. Pat. No.7,021,454, issued Apr. 4, 2006, which is incorporated herein byreference in its entirety. In some embodiments, the primary flow belt112 can have a length, measured from the infeed side 102 to thepass-through side 104 of between about 30″ to about 42″. The primaryflow belt 112 can have a width, measured in the conveying plane andgenerally orthogonal to the length, of between about 16″ to about 34″.The driver 114 can be coupled to the primary flow belt 112 via a rolleror other torque transmission feature. The primary flow belt 112 cancomprise a plurality of interconnected modules, such as plastic beltmodules comprising a body and a movable component. Modules that areadjacent to each other in the conveying direction can be hingedlyconnected, such as with a hinge pin.

With continued reference to FIG. 1, the second conveyance system 120,which can be a divert system, can move packages in a direction which isnon-parallel to the primary flow path of the conveyor system. Forexample, the divert system can move packages in a direction not parallelto the x-axis. As shown in the illustrated embodiment, the divertersystem 120 can move packages in a direction which is generallyorthogonal to the primary flow path of the conveyor system (e.g., thediverter system 120 can move packages in a direction along the y-axis).

The diverter system 120 can include a diverter belt 122. The diverterbelt 122 can extend from the first divert side 106 and/or the seconddivert side 108 of the modular transfer unit 100. The diverter belt 122can overlap at least partially with the primary flow belt 112. Thediverter system 120 can include a driver 124, such as a motor, which canbe directly coupled to the diverter belt 122 or indirectly coupled viaone or more intermediate components, such as gears. The driver 124 canmove the diverter belt 122 in a direction from the second divert side108 to the first divert side 106 of the modular transfer unit 100. Insome embodiments, the driver 124 can move the diverter belt 122 in adirection from the first divert side 106 to the second divert side 108of the modular transfer unit 100. The driver 124 can be reversible orintermediate components between the driver 124 and the diverter belt 122can allow the driver 124 to drive the diverter belt 122 in reverse.

In some embodiments, the diverter belt 122 comprises a non-modular belt,such as a fabric conveyor belt. In certain embodiments, the diverterbelt 122 can be a Habasit NSW-5ELAV. In some variants, the diverter belt122 comprises a plurality of interconnected modules, such as plasticbelt modules. Modules that are adjacent each other in the conveyingdirection can be hingedly connected, such as with a hinge pin. Thedriver 124 can be coupled to the diverter belt 122 via a roller. In someimplementations, the roller can be a 1.9″ diameter roller.

With continued reference to FIG. 1, the modular transfer unit 100 caninclude a frame 130 which can be used to support one or more componentsof the modular transfer unit 100. For example, as shown in theillustrated embodiment, the frame 130 can support components of theprimary flow system 110 and the diverter system 120. As such, themodular transfer unit 100 can be a standalone, self-contained systemcapable of operating separately from a conveyor system. In someimplementations, the housing 130 can be sized to fit between componentsof a conveyor system. This can beneficially allow the modular transferunit 100 to be implemented on an as-needed basis in a conveyor system.In doing so, the modular transfer unit 100 can be swapped from oneposition in a conveyor system to another position in the conveyor systemdepending on the needs of the operator. In some implementations, thehousing 130 can be sized to be retrofitted to existing conveyor systems.

In some embodiments, the electronics of the modular transfer unit 100can be run at low voltages. In some instances, this can allow themodular transfer unit 100 to be utilized without running electricalwires through a rigid conduit (e.g., electrical metallic tubing) therebyreducing overall complexity and costs for the modular transfer unit 100.In some embodiments, the electronics of the modular transfer unit 100are configured to operate at low voltages, such as at or below about50V. In some embodiments, the electronics of the modular transfer unit100 are configured to operate at voltages of approximately 24V or less.

With reference next to FIG. 2, a schematic of the primary flow belt 112and the diverter belt 122 of the modular transfer unit 100 isillustrated. As shown, the primary flow belt 112 can be positioned abovethe diverter belt 122 with movable components 116 of the primary flowbelt 112 contacting the diverter belt 122. The movable components 116can have one or more translational and/or rotational degrees of freedom.For example, the movable components 116 can be in the form of ballswhich provide three rotational degrees of freedom. As another example,the movable components 116 can be in the form of rollers which provideone degree of rotational freedom.

The movable components 116 can move in response to movement of theprimary flow belt 112 and/or the diverter belt 122. As shown in theillustrated embodiment, the movable components 116 can rotate about thex-axis (represented by arrow 118) in response to translation of thediverter belt 122 in a direction along the y-axis (represented by arrow126). A package (not shown) positioned on the primary flow belt 112 andcontacting the movable components 116 could thereby translate in adirection along the y-axis. This can allow the diverter belt 122 toredirect or divert packages in a direction which is generally orthogonalto the primary flow path. In several embodiments, when the movablecomponents 116 pass over the diverter belt 122, the movable components116 are in continuous contact with the diverter belt 122. In someimplementations, the diverter belt 122 is vertically fixed relative tothe primary flow belt 112. For example, in some embodiments, thediverter belt 122 as a whole does not move up and down and/or into andout of engagement with the movable components 116. In some embodiments,the diverter belt 122 is maintained in constant contact with and/or iscontinuously engaged with (e.g., abutted against) at least one of themovable components 116, such as the protruding lower portion of at leastone spherical ball. In certain embodiments, the primary flow belt 112does not include one or more motors that rotate the movable components116 relative to other of the movable components 116 and/or a base of theprimary flow belt in which the movable components 116 are journaled.

While the modular transfer unit 100 was described as having a singleinfeed side 102, a single pass-through side 104, and two divert sides106, 108, it is to be understood that fewer or greater number of sidesmay be used (e.g., five or more sides). Moreover, it is to be understoodthat the modular transfer unit 100 can include two infeed sides and twodischarge/divert sides. For example, the modular transfer unit 100 mayreceive packages at sides 102, 106. Packages received at side 102 may bedischarged at side 104 or diverted to side 108. Packages received atside 106 may be discharged at side 108 or diverted to side 104. Themodular aspect of the modular transfer unit 100 can beneficially allowthe modular transfer unit 100 to be implemented in a wide variety ofconveyance systems.

With reference next to FIGS. 3 and 4, an embodiment of a modulartransfer unit 200 is illustrated. The modular transfer unit 200 caninclude components, features, and/or functionality which are the same orsimilar to those of other modular transfer units described herein, suchas modular transfer unit 100 described above.

With reference first to FIG. 3, the modular transfer unit 200 caninclude a primary flow belt 212. The primary flow belt 212 can comprisea modular conveyor belt, such as a belt made up hingedly-connected beltmodules (e.g., links). The primary flow belt 212 can include multiplemovable components 216 in the form of spherical balls. The primary flowbelt 212 can be operated via one or more drivers, such as motorizedrollers (not shown). Components of the modular transfer unit 200 can besupported by a frame 230. This can allow the modular transfer unit 200to be swapped in and out of a conveyor system on an as-needed basis.With reference next to FIG. 4, the modular transfer unit 200 can includea diverter belt 222 positioned beneath the primary flow belt 212. Thediverter belt 222 can run in a direction different from that of theprimary flow belt 212. For example, the diverter belt 222 can run in adirection which is generally perpendicular to that of the primary flowbelt 212.

With reference next to FIGS. 5 and 6, an embodiment of a modulartransfer unit 300 is illustrated. The modular transfer unit 300 caninclude components, features, and/or functionality which are the same orsimilar to those of other modular transfer units described herein, suchas modular transfer units 100, 200 described above.

As shown in the illustrated embodiment, the modular transfer unit 300can have an infeed side 302 at which the modular transfer unit 300 canreceive one or more packages (not shown) and a pass-through side 304 atwhich the modular transfer unit 300 can discharge these packages.Similar to the embodiments described above, the modular transfer unit300 can redirect or divert packages away from the primary flow path fromthe infeed side 302 to the pass-through side 304. For example, themodular transfer unit 300 can divert packages towards a first divertside 306 or a second divert side 308 of the modular transfer unit 300.

The modular transfer unit 300 can include a primary flow belt 312 havingmultiple movable components 316 in the form of balls. The primary flowbelt 312 can be operated via one or more drivers, such as motorizedrollers 314. The modular transfer unit 300 can include a diverter belt322 positioned beneath the primary flow belt 312. The diverter belt 322can run in a direction different from that of the primary flow belt 312.For example, the diverter belt 322 can run in a direction which isgenerally perpendicular to that of the primary flow belt 312.

With continued reference to FIG. 5, components of the modular transferunit 300 can be supported by a frame 330. This can allow the modulartransfer unit 300 to be swapped in and out of a conveyor system on anas-needed basis. As shown, the frame 330 can include one or moreinterconnects 332, such as the illustrated flanges. In some embodiments,the interconnects 332 can be sized to attach to other components of aconveyor system (not shown). Although three pairs of interconnects 332are shown, it is to be understood that a single pair can be used. Thespacing between the interconnects 332 can be chosen to allow the modulartransfer unit 300 to be coupled with other components of a conveyorsystem, such as a belted or roller take-away. In some embodiments, theinterconnects 332 do not attach to other components of the conveyorsystem. In certain implementations, the modular transfer unit 300 is astand-alone unit (e.g., is self-supporting and/or not physically securedto other components of the conveyor system).

The interconnects 332 may be removably coupled to the frame 330 and/ormovable relative to the frame 330. This can beneficially allow the frame330 to be utilized with a variety of different components of a conveyorsystem. For example, as shown in the illustrated embodiment, theinterconnects 332 are shown on a second divert side 308 of the modulartransfer unit 300 such that a component of the conveyor system can beconnected to the second divert side 308. The first divert side 306 doesnot include any interconnects. In such a configuration, a sorting boxmay be positioned on the first divert side 306 of the modular transferunit 300. It is to be understood that such interconnects 332 can be usedalong any portion of the modular transfer unit 300, such as the infeedside 302, the pass-through side 304, the first divert side 306 and/orsecond divert side 308.

With reference next to FIG. 6, the modular transfer unit 300 is shownwith additional components attached thereto. The frame 330 can includeone or more guide members 334, such as the illustrated L-shaped guides.The guide members 334 can beneficially ensure that packages traveling onthe modular transfer unit 300 are properly aligned and positioned priorto transferring off of the modular transfer unit 300. Although one pairof guide members 334 is shown, it is to be understood that multiplepairs can be used.

The guide members 334 may be removably coupled to the frame 330 and/ormovable relative to the frame 330. This can beneficially allow the guidemembers 334 to be utilized with a variety of different packages and/orcomponents of a conveyor system. For example, as shown in theillustrated embodiment, the guide members 334 are shown on a seconddivert side 308 of the modular transfer unit 300. It is to be understoodthat such guide members 334 can be used along any portion of the modulartransfer unit 300, such as the infeed side 302, the pass-through side304, the first divert side 306, and/or the second divert side 308. Asshown in the illustrated embodiment, the guide members 334 can beattached directly to the interconnects 332; however, it is to beunderstood that the guide members 334 can be standalone members.

As shown in the illustrated embodiment, the modular transfer unit 300can include one or more detection zones, such as the infeed detectionzone 342, pass-through detection zone 344, and second divert detectionzone 348. In some embodiments, information pertaining to the detectionzones can be relayed to a control system of the modular transfer unit300 and/or a control system of other components of the conveyor systemto which the modular transfer unit 300 is attached. This can allow thecontrol system to control the operation of the modular transfer unit 300based on the status of the packages on the modular transfer unit 300.For example, the infeed detection zone 342 can provide an indicationthat the modular transfer unit 300 has received a package at the infeedside 302 of the modular transfer unit 300. The pass-through detectionzone 344 can provide an indication that the modular transfer unit 300has discharged a package from the pass-through side 304 of the modulartransfer unit 300. The second divert detection zone 348 can provide anindication that the modular transfer unit 300 has diverted anddischarged a package from the second divert zone 308.

A fewer or greater number of detection zones can be utilized. Forexample, the modular transfer unit 300 can include a first divertdetection zone (not shown) which can provide an indication that themodular transfer unit 300 has diverted and discharged a package from thefirst divert side 306. Additional detection zones may be utilizedbetween the infeed side 302, the pass-through side 304, the first divertside 306, and/or the second divert side 308. This can beneficiallyenhance tracking and/or monitoring the status and/or location of thepackages on the modular transfer unit 300.

As shown in the illustrated embodiment, the detection zones areone-dimensional (e.g., linear) in the plane of the primary flow belt 312(e.g., the x-y plane). In some embodiments, the detection zones can beformed by a photo-eye. However, it is to be understood that other typesof sensors can be utilized, such as optical sensors, electromagneticsensors, weight sensors, and other types of sensors. Moreover, althoughthe detection zones of the illustrated embodiment are linear in theplane of the primary flow belt 312, it is to be understood that thedetection zones can be two-dimensional in the plane of the primary flowbelt 312 and/or three-dimensional.

In some embodiments, the modular transfer unit 300 can include anon-board controller or PLC (not shown) to which information pertainingto the detection zones 342, 344, 348 can be relayed. This canbeneficially allow the modular transfer unit 300 to further operate as astand-alone unit. In some implementations, the on-board controller orPLC can be connected to the conveyor system to which the modulartransfer unit 300 is attached. This can allow the modular transfer unit300 to receive instructions from the conveyor system about specificpackages being conveyed. Such instructions may include whether to allowthe package to pass through the modular transfer unit 300 or to bediverted from the primary flow path of the conveyor system.

Example Embodiments of Conveyor System Configurations with a ModularTransfer Unit

With reference to FIGS. 7 and 8, a schematic of a conveyor system 400with a modular transfer unit 410 is illustrated. FIG. 7 shows a package401 being conveyed along the conveyor system 400 along a primary flowpath (e.g., along the x-axis) prior to the package 401 being received bythe modular transfer unit 410. FIG. 8 shows the package 401 after beingreceived by the modular transfer unit 410 prior to being diverted orpassed through by the modular transfer unit 410. The modular transferunit 410 can include components, features, and/or functionality whichare the same or similar to those of other modular transfer unitsdescribed herein, such as modular transfer units 100, 200, 300 describedabove.

With reference first to FIG. 7, the conveyor system 400 can include aninflow component 402 which can be positioned at or proximate an inflowside 412 of the modular transfer unit 410. The inflow component can be,for example, a belted or roller conveyor unit which can deliver thepackages to the infeed side 412 of the modular transfer unit 410. Theconveyor system 400 can include an outflow component 404 which can bepositioned at or proximate a pass-through side 414 of the modulartransfer unit 410. In some embodiments, the outflow component can be abelted or roller conveyor unit which can receive packages from thepass-through side 414 of the modular transfer unit 410 and convey suchpackages to another location (e.g., a belted or roller “take-away”). Insome embodiments, the outflow component 404 can be a bin or otherreceptacle which can receive the package. The conveyor system 400 caninclude a first diverted component 406 and/or a second divertedcomponent 408 which can be positioned at or proximate a first divertside 416 and/or second divert side 418 respectively of the modulartransfer unit 410. In some embodiments, the first diverted component 406and/or second diverted component 408 can be a belted or roller conveyorunit which can receive packages from the first divert side 416 and/orsecond divert side 418 respectively and convey such packages to anotherlocation. In some embodiments, the first diverted component 406 and/orsecond diverted component 408 can be a bin or other receptacle which canreceive the package.

Although a gap is shown between components 402, 404, 406, 408 of theconveyor system 400 and the modular transfer unit 410, it is to beunderstood that the components can be positioned adjacent to and/orsubstantially flush with the modular transfer unit 410. In instanceswhere a gap between one or more of the components 402, 404, 406, 408 ofthe conveyor system 400 and the modular transfer unit 410 exists, adevice may be utilized to fill in the gap. For example, a plate may bepositioned between one or more of the components 402, 404, 406, 408 ofthe conveyor system 400 and the modular transfer unit 410. As anotherexample, a roller may be positioned between one or more of thecomponents 402, 404, 406, 408 of the conveyor system 400 and the modulartransfer unit 410. In some implementations, the roller may be unpowered(e.g., an idler roller); however, it is to be understood that the rollermay be powered. This can allow the roller to advance the package betweencomponents of the conveyor system 400 and the modular transfer unit 410.A powered roller can be beneficial in instances where a package maypotentially remain stagnant in the gap between the component of theconveyor system 400 and the modular transfer unit 410 exists.

As shown in the illustrated embodiment, the modular transfer unit 410can include one or more detection zones formed by one or more sensors.As shown, the modular transfer unit 410 includes an infeed sensor 432which establishes an infeed detection zone 442, a discharge sensor 434which establishes a pass-through detection zone 444, a first divertsensor 436 which establishes a first divert detection zone 446, and/or asecond divert sensor 438 which establishes a second divert detectionzone 448. In some embodiments, the sensors can communicate with acontrol system of the modular transfer unit 410 and/or a control systemof other components of the conveyor system to which the modular transferunit 410 is attached. This can allow such a control system to controlthe operation of the modular transfer unit 410 based on the status ofthe packages on the modular transfer unit 410.

With continued reference to FIG. 7, the infeed detection zone 442 canprovide an indication that the modular transfer unit 410 has received apackage from the inflow component 402 of the conveyor system 400. Assuch, when the package 401 is conveyed from inflow component 402 of theconveyor system 400 to the modular transfer unit 410, as shown by thetransition between FIG. 7 and FIG. 8, the modular transfer unit 410 canproceed with passing the package 401 through the modular transfer unit410 to the outflow component 404 of the conveyor system 400 or divertingthe package 401 to either the first diverted component 406 or the seconddiverted component 408 of the conveyor system 400.

With reference to FIG. 8, diversion of the package may occur at a“divert zone” 450, which is a position at which the package may bediverted and received by component 406 and/or component 408 of theconveyor system 400. As shown in the illustrated embodiment, thecomponents 406, 408 of the conveyor system are arranged such that themodular transfer unit 410 can have a single divert zone 450; however, itis to be understood that the modular transfer unit 410 can have multipledivert zones. For example, multiple components (e.g., belted or roller“take-aways”) may be positioned along one or both divert sides 416, 418.As another example, the positioning of components 406, 408 may only bepartially aligned, or not aligned at all, such that each form separatedivert zones.

The pass-through detection zone 444 can provide an indication that themodular transfer unit 410 has passed a package 401 through the modulartransfer unit 410 and to the outflow component 404 of the conveyorsystem 400. The first divert detection zone 446 can provide anindication that the modular transfer unit 410 has diverted a package 401to the first diverted component 406 of the conveyor system 400. Thesecond divert detection zone 448 can provide an indication that themodular transfer unit 410 has diverted a package 401 to the seconddiverted component 408 of the conveyor system 400.

A fewer or greater number of detection zones can be utilized. Forexample, additional detection zones may be utilized between the infeedside 402, the pass-through side 404, the first divert side 406, and/orthe second divert side 408. This can beneficially enhance monitoring thestatus/location of the packages on the modular transfer unit 410.

Although the detection zones 442, 444, 446, 448 are positioned betweenthe components 402, 404, 406, 408 of the conveyor system 400 and themodular transfer unit 410, it is to be understood that one or more ofthese detection zones can be positioned along the modular transfer unit410 (as shown, for example, in the embodiment of modular transfer unit300 described in connection with FIG. 6). It is also to be understoodthat one or more of these detection zones can be positioned alongcomponents of the conveyor system 400.

As shown in the illustrated embodiment, the detection zones areone-dimensional (e.g., linear) in the plane of the conveyor system 400(e.g., the x-y plane). In some embodiments, the detection zones can beformed by a photo-eye. However, it is to be understood that other typesof sensors can be utilized, such as optical sensors, electromagneticsensors, weight sensors, and other types of sensors. Moreover, althoughthe detection zones of the illustrated embodiment are linear in theplane of the conveyor system 400, it is to be understood that thedetection zones can be two-dimensional in the plane of the conveyorsystem 400 and/or three-dimensional.

With reference next to FIG. 9, a schematic of a conveyor system 500 withmultiple modular transfer units 520, 522 is illustrated. Modulartransfer units 520, 522 can include components, features, and/orfunctionality which are the same or similar to those of other modulartransfer units described herein, such as modular transfer units 100,200, 300, 410 described above.

The conveyor system 500 can include multiple components which arepositioned at or proximate the modular transfer units 520, 522. As shownin the illustrated embodiment, the conveyor system 500 can includeconveyors 510, 512, 514 having belts 510 a, 512 a, 514 a and conveyors516, 518 having rollers 516 a, 518 a. In some embodiments, the belts 510a, 512 a, 514 a and/or rollers 516 a, 518 a can be powered to conveypackages across the conveyors 510, 512, 514, 516, 518. However, it is tobe understood that one or more of these components can be passive orunpowered. For example, the conveyors 516, 518 may be oriented with adownward slope such that packages can pass therethrough via gravity.

As shown in the illustrated embodiment, the conveyor 510 can be aninflow component positioned at or proximate an infeed side of themodular transfer unit 520. The conveyor 510 can deliver packages to theinfeed side of the modular transfer unit 520. The conveyors 512, 514 canbe first and second diverted components respectively which arepositioned at or proximate a first and second divert side of the modulartransfer unit 520. The conveyors 512, 514 can divert packages to otherlocations of the conveyor system 500.

The conveyor 516 can be an outflow component with respect to the modulartransfer unit 520 and positioned at or proximate a pass-through side ofthe modular transfer unit 520. The conveyor 516 can be an inflowcomponent with respect to the modular transfer unit 522 and positionedat or proximate an infeed side of the modular transfer unit 522. Theconveyor 516 can deliver packages which are passed through the modulartransfer unit 520 to the modular transfer unit 522. The conveyor 518 canbe a diverted component which is positioned at or proximate a divertside of the modular transfer unit 522. As shown in the illustratedembodiment, in some implementations the conveyor system 500 may not havea corresponding outflow component for the modular transfer unit 522 oran additional diverted component. However, it is to be understood thatsuch components may be added.

With reference to FIG. 10, a schematic of a conveyor system 600 withmultiple modular transfer units 620, 622, 624, 626 is illustrated. Themodular transfer units 620, 622, 624, 626 can include components,features, and/or functionality which are the same or similar to those ofother modular transfer units described herein, such as modular transferunits 100, 200, 300, 410, 520, 522 described above.

As shown in the illustrated embodiment, the conveyor system 600 caninclude conveyors 610, 612 arranged sequentially. Conveyor 612 can be aninflow component positioned at or proximate an infeed side of themodular transfer unit 620. Component 612 can deliver packages, such aspackages 602, 604, 606, 608, to the infeed side of the modular transferunit 620. As shown, the modular transfer units 620, 622, 624, 626 arearranged sequentially which can beneficially function as a compactsortation array. A package can sequentially pass through one or more ofthe modular transfer units 620, 622, 624, 626. At each modular transferunit, a determination can be made by the modular transfer unit or theconveyor system 600 as to whether the package should be diverted intoone of the bins, such as bins 630, 632, 634, 636, 638, 640, 642, 644,646, adjacent to that modular transfer unit or whether the packageshould be passed through to the next modular transfer unit. Due to themodular nature of the modular transfer units 620, 622, 624, 626, thissortation array can be modified on-the-fly. For example, one or moremodular transfer units can be added in the event that additionalsortation is desired or one or more of the existing modular transferunits 620, 622, 624, 626 can be removed if less sortation is desired.

While bins are shown in FIG. 10, it is to be understood that othercomponents, such as belted or roller conveyors, can be utilized in lieuof one or more of the bins.

Example Methods of Transferring a Package

Referring now to FIG. 11, a flowchart of an embodiment of a method 700for transferring a package using a modular transfer system, such asmodular transfer systems 100, 200, 300, 410, 520, 522, 620, 622, 624,626, is shown. In some embodiments, the system and method 700 is astand-alone modular transfer unit, such as modular transfer units 100,200, 300, 410, 520, 522, 620, 622, 624, 626 described above. Forexample, the method 700 can be implemented on a modular transfer unitwithout connecting the modular transfer unit to a conveyor system, suchas conveyor systems 400, 500, 600 described above. In other embodiments,the method 700 can be implemented by a conveyor system. In someembodiments, the method 700 can be implemented by the modular transferunit in conjunction with the conveyor system to which the modulartransfer unit is attached. For purposes of the disclosure below,reference may be made to components of the conveyor system 400 and themodular transfer units 100 and 410 described above in connection withFIGS. 1, 2, 7, and 8. However, it is to be understood that this methodcan be implemented in any of the conveyor systems and/or modulartransfer units described herein. Moreover, it is to be understood thatin some embodiments, the method 700 may instead be performed by themodular transfer unit separately from the conveyor system.

The method 700 can start at block 710 where a modular transfer unit,such as modular transfer unit 410, detects a package at an infeed sideof the modular transfer unit. The modular transfer unit can perform thisprocess via receiving a signal from a sensor, such as infeed sensor 432,indicating the existence of a package within a detection zone, such asinfeed detection zone 442, positioned at or proximate an infeed side ofthe modular transfer unit. For example, the system can transmitelectrical signals to and from the infeed sensor via an interface whichcan be coupled, physically or wirelessly, to a controller or PLC of themodular transfer unit.

The method 700 can then move to block 720 where the modular transferunit moves the package along a conveyance direction. In someembodiments, the conveyance direction can be along the primary flow pathfor the package. For example, with reference to the modular transferunit 100 described in connection with FIGS. 1 and 2, the modulartransfer unit 100 can moved the package in a direction along the primaryflow path (e.g., along the direction of the x-axis) by operating theprimary flow belt 112. However, it is to be understood that the modulartransfer unit can operate other belts depending on the specific side atwhich the package is received. This may be implemented, for example, ininstances where two or more sides of the modular transfer unit are“infeed” sides.

The method 700 can then move to block 730 where a determination is madeas to whether or not the package is at a divert zone, such as divertzone 450 discussed in connection with FIG. 8. Should a determination bemade that the package is not yet at the divert zone, the method 700 canmove back to block 720 and further move the package in the conveyancedirection. Should a determination be made that the package is at thedivert zone, the method 700 can move to block 720 and further move thepackage in the conveyance direction.

In some embodiments, this determination can be made based on the amountof time which has elapsed after detection of the package at the infeedside of the modular transfer unit at block 710. For example, afterdetecting the package at infeed detection zone 442, a timer can commencewhen the package is being conveyed at block 720. Upon running the motorfor a certain period of time, which may be pre-set from the factory orprogrammed by the operator, the modular transfer unit can assume thatthe package is now at the divert zone. In some implementations, thetimer can begin after the package is no longer detected at the infeeddetection zone which can signify that a trailing edge of the package haspassed through the infeed detection zone. This can be beneficial inensuring that the trailing edge is accounted for prior to beingdiverted. In some implementations, the timer can begin after the packageis first detected at the infeed detection zone which can signify that aleading edge of the package has passed through the infeed detectionzone. In some implementations, the timer can account for the amount oftime which has passed between the package being detected and the packageno longer being detected. In so doing, the timer can account for thesize of the package. This can beneficially center the package along thedivert zone.

In some embodiments, this determination can be made based on theoperation of a driver, such as a motorized roller, after detection ofthe package at the infeed side of the modular transfer unit at block710. For example, after detecting the package at infeed detection zone442, the system can determine the amount of distance traveled by theprimary flow belt based on operational parameters of the motorizedroller (e.g., rotational speed or velocity). In some embodiments, thedriver may be a pulse-width modulated (“PWM”) motor and the system candetermine operational parameters based on the amount of “pulses” sent tothe PWM motor. Upon reaching a certain operational amount, which may bepre-set from the factory or programmed by the operator, the modulartransfer unit can assume that the package is now at the divert zone.

In some implementations, the system can monitor operation of the driverafter the package is no longer detected at the infeed detection zonewhich can signify that a trailing edge of the package has passed throughthe infeed detection zone. This can be beneficial in ensuring that thetrailing edge is accounted for prior to being diverted. In someimplementations, the system can monitor operation of the driver afterthe package is first detected at the infeed detection zone which cansignify that a leading edge of the package has passed through the infeeddetection zone. In some implementations, the system can take intoaccount the size of the package. For example, the system can monitor theoperation of the monitor at the time the package is first detected atthe infeed detection zone until the package is no longer detected by theinfeed detection zone. In so doing, the timer can account for the sizeof the package. This can beneficially center the package along thedivert zone.

With continued reference to FIG. 11, the method 700 can then move toblock 740 where a determination is made as to whether the package is tobe diverted or is intended to be “passed through” or conveyed along theprimary flow path. In some embodiments, a signal can be provided to thesystem providing information with respect to the package. This signalcan be generated based on an indicator on the package including, but notlimited to, electromagnetic devices such as NFC and RFID and/or printedcodes such as a barcode or QR code. In some embodiments, this signal canbe generated by user input. In some embodiments, the system can includetwo or more divert sides. In such embodiments, the signal providinginformation regarding whether to divert or pass through the package canfurther include information regarding the specific direction to divertthe package.

If the package is to be diverted, the method 700 can move to block 750 aand move the package in the divert direction. In some embodiments, thedivert direction can be in a direction different from the primary flowpath for the package. For example, with reference to the modulartransfer unit 100 described in connection with FIGS. 1 and 2, themodular transfer unit 100 can moved the package in a direction along theprimary flow path (e.g., along the direction of the y-axis) by operatingthe diverter belt 122. However, it is to be understood that the modulartransfer unit can operate other belts depending on the specific side atwhich the package is received. This may be implemented, for example, ininstances where two or more sides of the modular transfer unit are“divert” sides. In some embodiments, other belts of the system can bedisabled as the package is diverted. This can be beneficial in instanceswhere the primary flow belt and diverter belt, such as primary flow belt112 and diverter belt 122, are oriented generally perpendicular relativeto each other and a 90-degree transfer is desired.

If the package is not to be diverted, the method 700 can move to block750 b and move the package in the conveyance direction to be “passedthrough” the system. In some embodiments, the conveyance direction canbe along the primary flow path for the package. For example, withreference to the modular transfer unit 100 described in connection withFIGS. 1 and 2, the modular transfer unit 100 can move the package in adirection along the primary flow path (e.g., along the direction of thex-axis) by operating the primary flow belt 112. However, it is to beunderstood that the modular transfer unit can operate other beltsdepending on the specific side at which the package is received. Thismay be implemented, for example, in instances where two or more sides ofthe modular transfer unit are “infeed” sides.

With continued reference to FIG. 11, in the event that the method 700moved to block 750 a, the method 700 can move to block 760 a where adetermination is made as to whether or not the package has been divertedand discharged from the system. Should a determination be made that thepackage has not yet been diverted and discharged, the method 700 canmove back to block 750 a and further move the package in the divertdirection. Should a determination be made that the package has beendiverted and discharged, the method 700 can move to block 770 where themethod can end.

The modular transfer unit can perform this process via receiving asignal from a sensor, such as first and/or second divert sensors 436,438, indicating the existence of a package within a detection zone, suchas first and/or second divert zones 446, 448 positioned at or proximatedivert sides of the system. For example, the system can transmitelectrical signals to and from the divert sensor via an interface whichcan be coupled, physically or wirelessly, to a controller or PLC of themodular transfer unit. In some embodiments, this determination can bemade after the package is no longer detected at the divert detectionzone which can signify that a trailing edge of the package has passedthrough the divert detection zone.

In some embodiments, this determination can be made based on the amountof time which has elapsed after the divert operation commenced. Forexample, after running the diverter belt, a timer can commence when thepackage is being diverted. Upon running the motor for a certain periodof time, which may be pre-set from the factory or programmed by theoperator, the system can assume that the package has been dischargedfrom the divert zone.

In some embodiments, this determination can be made based on theoperation of a driver, such as a motorized roller, after the divertoperation commenced. For example, after the divert operation commenced,the system can determine the amount of distance traveled by the primaryflow belt based on operational parameters of the motorized roller (e.g.,rotational speed or velocity). In some embodiments, the driver may be apulse-width modulated (“PWM”) motor and the system can determineoperational parameters based on the amount of “pulses” sent to the PWMmotor. Upon reaching a certain operational amount, which may be pre-setfrom the factory or programmed by the operator, the system can assumethat the package has been discharged from the divert zone.

With continued reference to FIG. 11, in the event that the method 700moved to block 750 b, the method can move to block 760 b where adetermination is made as to whether or not the package has been passedthrough and discharged from the system. Should a determination be madethat the package has not yet been passed through and discharged, themethod 700 can move back to block 750 b and further move the package inthe conveyance direction. Should a determination be made that thepackage has been passed through and discharged, the method 700 can moveto block 770 where the method can end.

The modular transfer unit can perform this process via receiving asignal from a sensor, such as discharge sensor 434, indicating theexistence of a package within a detection zone, such as discharge zone444 positioned at or proximate a pass-through side of the system. Forexample, the system can transmit electrical signals to and from thedivert sensor via an interface which can be coupled, physically orwirelessly, to a controller or PLC of the modular transfer unit. In someembodiments, this determination can be made after the package is nolonger detected at the discharge zone which can signify that a trailingedge of the package has passed through the discharge zone.

In some embodiments, this determination can be made based on the amountof time which has elapsed after the pass through operation commenced.For example, after running the primary flow belt, a timer can commencewhen the package is being passed through. Upon running the motor for acertain period of time, which may be pre-set from the factory orprogrammed by the operator, the system can assume that the package hasbeen passed through and discharged from the discharge zone.

In some embodiments, this determination can be made based on theoperation of a driver, such as a motorized roller, after the passthrough operation commenced. For example, after the pass throughoperation commenced, the system can determine the amount of distancetraveled by the primary flow belt based on operational parameters of themotorized roller (e.g., rotational speed or velocity). In someembodiments, the driver may be a pulse-width modulated (“PWM”) motor andthe system can determine operational parameters based on the amount of“pulses” sent to the PWM motor. Upon reaching a certain operationalamount, which may be pre-set from the factory or programmed by theoperator, the system can assume that the package has been dischargedfrom the discharge zone.

In some embodiments, the system can be operated such that the method isperformed fully for a package prior to performing the method for asubsequent package. In some embodiments, the system can be operated suchthat the method is performed partially for a package prior to performingthe method for a subsequent package. For example, the system may beimplementing block 750 b on a first package and implementing block 720on a second package.

It is to be understood that the steps of method 700 can be interchangedor repeated. For example, in embodiments where more than a single divertzone is present, step 740 may return to step 720 if a determination ismade not to divert the package at a divert zone. This repetition mayoccur until the package has either been diverted or has reached thefinal divert zone. Moreover, it is to be understood that one or more ofthe steps of method 700 can be omitted. For example, in someembodiments, the method 700 can omit any of steps 760 a, 760 b.

Example Embodiments of a Multi-Zone Modular Transfer Unit

With reference to FIG. 12, a schematic of a modular transfer unit 800 isillustrated. The modular transfer unit 800 can include components,features, and/or functionality which are the same or similar to those ofother modular transfer units described herein, such as modular transferunits 100, 200, 300, 410, 520, 522, 620, 622, 624, 626 described above.

The modular transfer unit 800 can have an infeed side 802 at which themodular transfer unit 800 can receive one or more packages from aconveyor system. The modular transfer unit 800 can allow packages topass through the modular transfer unit 800 in a primary flow path (e.g.,in a direction along the x-axis). The modular transfer unit 800 can havea pass-through side 804 at which the modular transfer unit 800 candischarge packages which are intended to be passed through the modulartransfer unit 800. The modular transfer unit 800 can redirect or divertpackages from the primary flow path. The modular transfer unit 800 canhave a first divert side 806 and/or a second divert side 808 at whichthe modular transfer unit 800 can discharge packages which are intendedto be diverted by the modular transfer unit 800.

The modular transfer unit 800 can include a first conveyance system 810and a second conveyance system 820. The first conveyance system 810,which can be a primary flow system, can move packages along a directionof the primary flow path (e.g., in a direction along the x-axis). Asshown, the primary flow system 810 can include a primary flow belt 812which extends between the infeed side 802 and the pass-through side 804of the modular transfer unit 800. The primary flow system 810 caninclude a driver 814, such as a motor, which can be directly coupled tothe primary flow belt 812 or indirectly coupled via one or moreintermediate components, such as gears. The driver 814 can move theprimary flow belt 812 in a direction from the infeed side 802 to thepass-through side 804 of the modular transfer unit 800. In someembodiments, the driver 814 can move the primary flow belt 812 in adirection from the pass-through side 804 to the infeed side 802 of themodular transfer unit 800. The driver 814 can be reversible orintermediate components between the driver 814 and the primary flow belt812 can allow the driver 814 to drive the primary flow belt 812 inreverse.

With continued reference to FIG. 12, the second conveyance system 820,which can be a divert system, can move packages in a direction which isnon-parallel to the primary flow path of the conveyor system (e.g., in adirection not parallel to the x-axis). As shown in the illustratedembodiment, the diverter system 820 can move packages in a directionwhich is generally orthogonal to the primary flow path of the conveyorsystem (e.g., the diverter system 820 can move packages in a directionalong the y-axis). The diverter system 820 can include a first diverterbelt 822 a and a second diverter belt 822 b which each extend from thefirst divert side 806 and/or the second divert side 808 of the modulartransfer unit 800 and/or overlaps at least partially with the primaryflow belt 812. The diverter system 820 can include a first driver 824 aand a second driver 824 b, such as motors, which can be directly coupledto the diverter belts 822 a, 822 b or indirectly coupled via one or moreintermediate components, such as gears. The drivers 824 a, 824 b canmove the diverter belts 822 a, 822 b in a direction from the seconddivert side 808 to the first divert side 806 of the modular transferunit 800. In some embodiments, the drivers 824 a, 824 b can move thediverter belts 822 a, 822 b in a direction from the first divert side806 to the second divert side 808 of the modular transfer unit 800. Thedriver 824 can be reversible or intermediate components between thedrivers 824 a, 824 b and the diverter belts 822 a, 822 b can allow thedrivers 824 a, 824 b to drive the diverter belts 822 a, 822 b inreverse.

The modular transfer unit 800 can include a frame 830 which can be usedto support one or more components of the modular transfer unit 800. Forexample, as shown in the illustrated embodiment, the frame 830 cansupport components of the primary flow system 810 and the divertersystem 820. As such, the modular transfer unit 800 can be a standalone,self-contained system capable of operating separately from a conveyorsystem. In some implementations, the housing 830 can be sized to fitbetween components of a conveyor system. This can beneficially allow themodular transfer unit 800 to be implemented on an as-needed basis in aconveyor system. In so doing, the modular transfer unit 800 to beswapped from one position in a conveyor system to another position inthe conveyor system depending on the needs of the operator. In someimplementations, the housing 830 can be sized to be retrofitted toexisting conveyor systems.

In some embodiments, the electronics of the modular transfer unit 800can be run at low voltages. In some instances, this can allow themodular transfer unit 800 to be utilized without running electricalwires through a conduit thereby reducing overall complexity and costsfor the modular transfer unit 800. In some embodiments, the electronicsof the modular transfer unit 800 can be run at low voltages, such as ator below about 50V. In some embodiments, the electronics of the modulartransfer unit 100 are configured to operate at voltages of approximately24V or less.

With reference next to FIG. 13, an embodiment of a modular transfer unit900 is illustrated in a partial cut-away view. The modular transfer unit900 can include components, features, and/or functionality which are thesame or similar to those of other modular transfer units describedherein, such as modular transfer units 100, 200, 300, 410, 520, 522,620, 622, 624, 626, 800 described above.

The modular transfer unit 900 can have an infeed side 902 at which themodular transfer unit 900 can receive one or more packages from aconveyor system. The modular transfer unit 900 can allow packages topass through the modular transfer unit 900 in a primary flow path (e.g.,in a direction along the x-axis). The modular transfer unit 900 can havea pass-through side 904 at which the modular transfer unit 900 candischarge packages which are intended to be passed through the modulartransfer unit 900. The modular transfer unit 900 can redirect or divertpackages from the primary flow path. The modular transfer unit 900 canhave a first divert side 906 and/or a second divert side 908 at whichthe modular transfer unit 900 can discharge packages which are intendedto be diverted by the modular transfer unit 900.

The modular transfer unit 900 can include a first conveyance system 910and a second conveyance system 920. The first conveyance system 910,which can be a primary flow system, can move packages along a directionof the primary flow path (e.g., in a direction along the x-axis). Asshown, the primary flow system 910 can include a primary flow belt 912which extends between the infeed side 902 and the pass-through side 904of the modular transfer unit 900. The primary flow belt 912 can includeone or more movable components 116 which can have one or moretranslational and/or rotational degrees of freedom. For example, themovable components 916 can be in the form of balls which provide threerotational degrees of freedom. As another example, the movablecomponents 916 can be in the form of rollers which provide one degree ofrotational freedom.

The primary flow system 910 can include a driver 914, such as amotorized roller, which can be directly coupled to the primary flow belt912 or indirectly coupled via one or more intermediate components, suchas gears. As shown in the illustrated embodiment, the driver 914 caninclude coupling features 918, such as sprockets, which can directlyengage the primary flow belt 912. The driver 914 can include multiplesprockets which can reduce the force applied by each sprocket on theprimary flow belt 912 as the driver 914 is operated. The spacing betweenthe sprockets can be chosen to allow movable components 916 to freelypass over the driver 914. For example, the movable components 916 canpass through the spaces between the sprockets. It is to be understoodthat the driver 914 can have other geometries appropriate for thestructure of the primary flow belt 912. The driver 914 can move theprimary flow belt 912 in a direction from the infeed side 902 to thepass-through side 904 of the modular transfer unit 900. In someembodiments, the driver 914 can move the primary flow belt 912 in adirection from the pass-through side 904 to the infeed side 902 of themodular transfer unit 900. The driver 914 can be reversible orintermediate components between the driver 914 and the primary flow belt912 can allow the driver 914 to drive the primary flow belt 912 inreverse.

With continued reference to FIG. 13, the second conveyance system 920,which can be a divert system, can move packages in a direction which isnon-parallel to the primary flow path of the conveyor system (e.g., in adirection not parallel to the x-axis). As shown in the illustratedembodiment, the diverter system 920 can move packages in a directionwhich is generally orthogonal to the primary flow path of the conveyorsystem (e.g., the diverter system 920 can move packages in a directionalong the y-axis). The diverter system 920 can include a first diverterbelt 922 a and a second diverter belt 922 b which extend from the firstdivert side 906 and/or the second divert side 908 of the modulartransfer unit 900 and/or overlaps at least partially with the primaryflow belt 912.

The diverter system 920 can include a first driver 924 a and a seconddriver 924 b, such as motorized rollers, which can be directly coupledto the diverter belts 922 a, 922 b or indirectly coupled via one or moreintermediate components, such as gears. The drivers 924 a, 924 b canmove the diverter belts 922 a, 922 b in a direction from the seconddivert side 908 to the first divert side 906 of the modular transferunit 900. In some embodiments, the drivers 924 a, 924 b can move thediverter belts 922 a, 922 b in a direction from the first divert side906 to the second divert side 908 of the modular transfer unit 900. Thedriver 924 can be reversible or intermediate components between thedrivers 924 a, 924 b and the diverter belts 922 a, 922 b can allow thedrivers 924 a, 924 b to drive the diverter belts 922 a, 922 b inreverse.

As shown in the illustrated embodiment, the modular transfer unit 900can include a support 930 extending between an edge of the primary flowbelt 912. This support 930 can include movable components, similar tothe movable components 916 of the primary flow belt 912. In someembodiments, this support 930 can be an idle or powered roller. Thesupport 930 can extend between a gap that exists between the primaryflow belt 912 and another component of the conveyor system positioned ator proximate the first divert side 906 of the modular transfer unit 900.

With continued reference to FIG. 13, the modular transfer unit 900 caninclude one or more detection zones formed by one or more sensors. Asshown, the modular transfer unit includes an infeed sensor 932 whichestablishes an infeed detection zone 942, a discharge sensor 934 whichestablishes a pass-through detection zone 944, a first divert sensor 936which establishes a first divert detection zone 946, and/or a seconddivert sensor 938 which establishes a second divert detection zone 948.In some embodiments, the sensors can communicate with a control systemof the modular transfer unit 900 and/or a control system of othercomponents of a conveyor system to which the modular transfer unit 900is attached. This can allow such a control system to control theoperation of the modular transfer unit 900 based on the status of thepackages on the modular transfer unit 900.

The infeed detection zone 942 can provide an indication that the modulartransfer unit 900 has received a package from an inflow component of theconveyor system. The pass-through detection zone 944 can provide anindication that the modular transfer unit 900 has passed a packagethrough the modular transfer unit 900 and to the outflow component of aconveyor system. The first divert detection zone 946 can provide anindication that the modular transfer unit 900 has diverted a package toa first diverted component of the conveyor system. The second divertdetection zone 948 can provide an indication that the modular transferunit 900 has diverted a package to a second diverted component of theconveyor system 900. A fewer or greater number of detection zones can beutilized. For example, additional detection zones may be utilizedbetween the infeed side 902, the pass-through side 904, the first divertside 906, and/or the second divert side 908. This can beneficiallyenhance monitoring the status/location of the packages on the modulartransfer unit 900.

The modular transfer unit 900 can include a frame 950 which can be usedto support one or more components of the modular transfer unit 900. Forexample, as shown in the illustrated embodiment, the frame 950 cansupport components of the primary flow system 910, the diverter system920, the support 930, and/or sensors 932, 934, 936, 938. As such, themodular transfer unit 900 can be a standalone, self-contained systemcapable of operating separately from a conveyor system. In someimplementations, the housing 950 can be sized to fit between componentsof a conveyor system. This can beneficially allow the modular transferunit 900 to be implemented on an as-needed basis in a conveyor system.In so doing, the modular transfer unit 900 to be swapped from oneposition in a conveyor system to another position in the conveyor systemdepending on the needs of the operator. In some implementations, thehousing 950 can be sized to be retrofitted to existing conveyor systems.

Embodiments of Conveyor System Configurations with Multi-Zone ModularTransfer Unit

With reference to FIGS. 14 and 15, a schematic of a conveyor system 1000with a modular transfer unit 1010 is illustrated. FIG. 14 shows packages1001 a, 1001 b after being received by the modular transfer unit 1010prior to being diverted or passed through by the modular transfer unit1010. FIG. 15 shows a package 1001 a after being received by the modulartransfer unit 1010 positioned between two divert zones. The modulartransfer unit 1010 can include components, features, and/orfunctionality which are the same or similar to those of other modulartransfer units described herein, such as modular transfer units 100,200, 300, 410, 520, 522, 620, 622, 624, 626, 800 described above. Forexample, although not shown in FIG. 14, it is to be understood thatsystem 1000 can include one or more detection zones, such as an infeeddetection zone, a pass-through detection zone, and one or more divertdetection zones, can be formed by one or more sensors.

With reference first to FIG. 14, the conveyor system 1000 can include aninflow component 1002 which can be positioned at or proximate an inflowside of the modular transfer unit 1010. The inflow component can be, forexample, a belted or roller conveyor unit which can deliver the packagesto the infeed side of the modular transfer unit 1010. The conveyorsystem 1000 can include an outflow component 1004 which can bepositioned at or proximate a pass-through side of the modular transferunit 1010. In some embodiments, the outflow component can be a belted orroller conveyor unit which can receive packages from the pass-throughside of the modular transfer unit 1010 and convey such packages toanother location (e.g., a belted or roller “take-away”). In someembodiments, the outflow component 1004 can be a bin or other receptaclewhich can receive the package.

The conveyor system 1000 can include a one or more diverted components1006 a, 1006 b, 1008 a, 1008 b which can be positioned at or proximate afirst divert side and/or second divert side respectively of the modulartransfer unit 1010. In some embodiments, the first diverted components1006 a, 1006 b and/or second diverted components 1008 a, 1008 b can be abelted or roller conveyor unit which can receive packages from the firstdivert side and/or second divert side respectively and convey suchpackages to another location. In some embodiments, the first divertedcomponents 1006 a, 1006 b and/or second diverted components 1008 a, 1008b can be a bin or other receptacle which can receive the package.

Although a gap is shown between components 1002, 1004, 1006 a, 1006 b,1008 a, 1008 b of the conveyor system 1000 and the modular transfer unit1010, it is to be understood that the components can be positionedadjacent to and/or substantially flush with the modular transfer unit1010. In instances where a gap between one or more of the components1002, 1004, 1006 a, 1006 b, 1008 a, 1008 b of the conveyor system 1000and the modular transfer unit 1010 exists, a device may be utilized tofill in the gap. For example, a support, such as support 930 describedabove in connection with FIG. 13, may be positioned between one or moreof the components 1002, 1004, 1006 a, 1006 b, 1008 a, 1008 b of theconveyor system 1000 and the modular transfer unit 1010.

As shown, packages 1008 a, 1008 b are positioned at one or more “divertzones” 1050 a, 1050 b, a position at which the package may be divertedand received by components 1006 a, 1006 b 1008 a, and/or 1008 b of theconveyor system 1000. As shown in the illustrated embodiment, components1006 a, 1006 b, 1008 a, 1008 b of the conveyor system 1000 are arrangedsuch that the modular transfer unit 1010 can have a single divert zone1050 a for components 1006 a, 1008 a and a second divert zone 1050 b forcomponents 1006 b, 1008 b. These divert zones 1050 a, 1050 b cancorrespond to the location of separate diverter belts, such as diverterbelts 922 a, 922 b discussed in connection with FIG. 13. In this manner,the modular transfer unit 1010 can divert one or both packages 1001 a,1001 b separately in different directions. For example, the modulartransfer unit 1010 can implement the method 700 described in connectionwith FIG. 11.

However, it is to be understood that the modular transfer unit 1010 canhave multiple divert zones. For example, multiple components (e.g.,belted or roller “take-aways”) may be positioned along one or bothdivert sides. As another example, the positioning of components 1006 a,1006 b, 1008 a, 1008 b may only be partially aligned, or not aligned atall, such that each form separate divert zones.

With reference next to FIG. 15, the package 1001 a is illustratedbetween divert zones 1050 a, 1050 b. As shown, in this position thepackage 1001 a can be translated in the primary flow path (e.g., in adirection along the x-axis) and/or translated in the divert path (e.g.,in a direction along the y-axis) in a similar fashion to that describedabove. In some embodiments, the package 1001 a can be rotated while inthis position via a velocity differential between the divert zones 1050a, 1050 b are operated. For example, the package 1001 a can be rotatedcounter-clockwise along the z-axis by having the second divert zone 1050b operate to move the package 1001 a towards components 1008 a, 1008 b(e.g., in a “negative” direction along the y-axis) while having thefirst divert zone 1050 a operate to move the package towards components1006 a, 1006 b (e.g., in a “positive” direction along the y-axis).Rotation in the counter-clockwise direction can be achieved by reversingoperation of the divert zones 1050 a, 1050 b.

Examples of Simultaneous Diversion and Rotation with a Multi-ZoneModular Transfer Unit

With reference to FIG. 16, a schematic of a modular transfer unit 1100is illustrated with a package 1001 shown in various phases of transferalong the modular transfer unit 1100. The modular transfer unit 1010 caninclude components, features, and/or functionality which are the same orsimilar to those of other modular transfer units described herein, suchas modular transfer units 100, 200, 300, 410, 520, 522, 620, 622, 624,626, 800, 900 described above.

As shown, the package 1101 passes through multiple “divert zones” 1110a, 1110 b, 1110 c, 1110 d, 1110 e. The divert zones 1110 a, 1110 b, 1110c, 1110 d, 1110 e, 1100 f can correspond to the location of separatediverter belts, such as diverter belts 922 a, 922 b, etc., such as isdiscussed in connection with FIG. 13. In various embodiments, thediverter belts, and thus the divert zones, can be operated at differentvelocities and/or directions. For example, a first diverter belt can bedriven toward a first lateral side of the primary flow belt (e.g., tothe left in the direction of travel of the primary flow belt) and asecond diverter belt can be driven toward a second lateral side of theprimary flow belt (e.g., to the right in the direction of travel of theprimary flow belt). In some embodiments, the second diverter belt can belongitudinally adjacent to the first belt. In some embodiments, one ormore additional diverter belts are positioned longitudinally between thefirst and second diverter belts. As illustrated, in several embodiments,the divert zones extend from one lateral side of the primary flow beltto the other lateral side of the primary flow belt. In variousembodiments, in the direction of travel of the primary flow belt thedivert zones extend across multiple of the movable components, such asat least 5, 10, 15 or more of the movable components.

In several embodiments, each of the diverter belts, and thus the divertzones, can be operated independent of the other diverter belts. Forexample, the diverter belt 1110 a can be operated at a first velocity,the diverter belt 1110 b can be operated at a second velocity, thediverter belt 1110 c can be operated at a third velocity, etc. Invarious embodiments, the divert zones 1110 a, 1110 b, 1110 c, 1110 d,1110 e, 1100 f can operate at different velocities. For example, asshown in the illustrated embodiment, the operational velocities of thedivert zones 1110 a, 1110 b, 1110 c, 1110 d, 1110 e, 1100 f can bechosen such that the package 1101 is simultaneously translated androtated as the package 1101 passes through the modular transfer unit1100. In some embodiments, a belt can operate to move the package 1101in the primary flow direction (e.g., along the x-axis). Each of thedivert zones 1110 a, 1110 b, 1110 c, 1110 d, 1110 e, 1100 f can operateto move the package 1001 a in the same divert direction (e.g., along they-axis) with each of the divert zones 1110 a, 1110 b, 1110 c, 1110 d,1110 e, 1100 f having progressively higher speeds of operation. As such,as the package 1101 is simultaneously moved in the primary flowdirection (e.g., along the x-axis), in the divert direction (e.g., alongthe y-axis), and rotated clockwise about the z-axis. In someimplementations, in the direction of travel of the primary flow belt,the velocities of the diverter belts increases. For example, thediverter belt 1110 a can be operated at a first velocity, the diverterbelt 1110 b can be operated at a second velocity that is greater thanthe first velocity, the diverter belt 1110 c can be operated at a thirdvelocity that is greater than the second velocity, etc. In certainimplementations, the difference in velocity between adjacent diverterbelts is less than or equal to about 20%. For example, if diverter belt1110 a is operating a velocity X, the maximum velocity of diverter belt1110 b is 1.2×. In certain implementations, the difference in velocitybetween adjacent diverter belts is less than or equal to about 50%.

Although each of the divert zones 1110 a, 1110 b, 1110 c, 1110 d, 1110e, 1100 f are shown operating in the same direction with differentspeeds, it is to be understood that one or more of the divert zones 1110a, 1110 b, 1110 c, 1110 d, 1110 e, 1100 f can operate in differentdirections and/or at the same speed. This can allow the package 1101 tobe rotated in different directions and/or discharged at differentlocations.

In some embodiments, the speeds of the divert zones 1110 a, 1110 b, 1110c, 1110 d, 1110 e, 1100 f can be chosen based on the positioning of thepackage 1101 prior to being received by the modular transfer unit 1100.For example, if the package 1101 is received closer to the side at whichthe package 1101 is to be discharged, the speeds of one or more of thedivert zones 1110 a, 1110 b, 1110 c, 1110 d, 1110 e, 1100 f may beslowed or may be reversed to ensure that the package is discharged atthe desired location and rotated to the desired amount.

Example Embodiments of Drivers

With reference to FIGS. 17 and 18, an embodiment of a drive roller ordriver 1200 is illustrated. The driver 1200 can be used to drive a beltof a modular transfer unit, such as those described herein. In someembodiments, the driver 1200 is used to drive the primary belt 112. Insome embodiments, the driver 1200 is used to drive the diverter belt122. In some embodiments, the driver 1200 can be used with a 2253RT belt(available from System Plast S.r.l.) or other belts with features thatare the same, or similar to, those described in U.S. Pat. No. 7,021,454,issued Apr. 4, 2006, which is incorporated herein by reference in itsentirety.

As shown in the illustrated embodiment, the driver 1200 can include ashaft 1210 to which the driver 1200 can be attached to a power source,such as a motor. The driver 1200 can include one or more sprockets 1220,having teeth 1222, which can engage structures of the belt which thedriver 1200 is intended to drive. Some conveyor drivers include one ortwo sprockets that engage with chains attached with the conveyor belt.This design is responsible for much of the noise of a conveyor systembecause all of the driving force is concentrated on the one or twochains and sprockets. In some embodiments, the driver 1200 can includean increased number of sprockets to reduce the amount of force appliedby each sprocket to the driven belt. For example, as shown in theillustrated embodiment, the driver 1200 can include at least 4, 6, 8,10, 12, 14, 16, or more sprockets. The increased number of sprockets canreduce the pressure applied by each of the sprockets individually, whichcan reduce the overall noise associated with use of the driver 1200.

In some implementations, the driver 1200 includes engagement regions1221. The engagement regions 1221 can provide an additional oralternative driving force on the belt. In various embodiments, theengagement regions 1221 comprise a radially outer surface of the driver1200. The engagement regions 1221 can engage with a bottom of the belt,such as in regions of the belt that are laterally between the movablecomponents 116. The friction between the engagement regions 1221 and thebelt can drive the belt.

In some implementations, the driver 1200 can include a plurality ofengagement regions 1221. The greater the number of engagement regions1221, the less pressure that each individual engagement region 1221needs to apply in order for there to be sufficient overall force (e.g.,through frictional engagement) to drive the belt. A reduction inpressure can promote safety (e.g., by reducing pinch pressure) and/orcan facilitate smoother and/or quieter operation of the belt (e.g., ascompared to a sprocket driven driver under the same conditions). Asshown in FIG. 17, in some implementations, engagement regions 1221 onends of the driver 1200 have a reduced axial width compared toengagement regions 1221 between the ends.

As shown, the sprockets 1220 and engagement regions 1221 can be combinedand/or intermixed. For example, an engagement region 1221 can belaterally bounded by sprockets 1220. In some embodiments, the driver1200 includes more sprockets 1220 than engagement regions 1221, such asa ratio of at least about 2:1.

The driver 1200 can include one or more recessed areas 1230 (e.g.,grooves). The recessed areas 1230 can be sized to allow movablecomponents of the belt, such as movable components 116 described inconnection with FIG. 2, to pass over the driver 1200. For example, incross section, as shown in FIG. 17, the recessed areas 1230 can besemi-circular (e.g., to accommodate the shape of movable components 116in the form of balls). In various embodiments, the recessed areas 1230is configured to receive a portion of the movable components 116, suchas a portion of the movable components 116 that protrudes downwardly. Insome implementations, the movable components largely do not contact thedriver 1200 because of the recessed areas 1230. This can facilitatesmooth and quiet operation of the belt while the belt is being driven bythe driver 1200.

With reference to FIG. 19, an embodiment of a driver 1300 and belt 1330is shown. The driver 1300 can be used to drive the belt 1330 of amodular transfer unit such as those described herein. For example, thebelt 1330 can be a 2253RT belt (available from System Plast S.r.l.) orother belts with features that are the same, or similar to, thosedescribed in U.S. Pat. No. 7,021,454, issued Apr. 4, 2006, which isincorporated herein by reference in its entirety. In some embodiments,the driver 1300 is used to drive the primary belt 112. In someembodiments, the driver 1300 is used to drive the diverter belt 122.

The driver 1300 can include any of the features of the driver 1200. Forexample, the driver 1300 can include a shaft (not shown) to which thedriver 1300 can be attached to a power source, such as a motor. Thedriver 1300 can include one or more sprockets 1310, having teeth 1312,which can engage structures of the belt 1330. For example, the teeth1312 can engage ribbed features 1332 of the belt 1330. These ribbedfeatures 1332 may be, for example, a coupling between links of the belt1330. The teeth 1312 may be sized to fit within recesses 1334 of thebelt 1330. Although the driver 1300 is shown extending only partiallyacross the belt 1330, it is to be understood that the driver 1300 canextend further across the lateral width of the belt 1330. For example,the driver 1300 can extend across the width of the belt 1330.Additionally, although the driver 1300 is shown with only two sprockets,it is to be understood that the driver 1300 can include more sprockets,such as is described above on connection with the driver 1200.

The driver 1300 can include one or more recessed areas 1320, which canbe similar or identical to the recessed areas 1230 described above. Therecessed areas 1320 can be sized to allow movable components 1336 of thebelt 1330 to pass over the driver 1300. This can facilitate smoothoperation of the belt 1330 while the belt 1330 is being driven by thedriver 1300. The

The driver 1300, or any driver described herein, can be lagged. A laggeddriver can comprise a coating and/or sheath on a base of the driver,such as a plastic or rubber coating on a metal or plastic base. A laggeddriver can enhance the engagement of the driver with the belt 1330, suchas by increasing the frictional engagement between the driver 1300 andthe belt. In some embodiments, a lagged roller can dampen the noise ofthe engagement between the driver 1300 (or a component thereof such asthe sprockets 1310) and the ribbed features 1332. In certainimplementations, at least a portion of the driver 1300 (e.g., a radiallyouter surface and/or the sprockets 1310) comprises urethane,thermoplastic rubber, ethylene propylene diene monomer (EPDM) rubber,nylon, or other materials. In some variants, the driver 1300 isconfigured to reduce noise associated with the engagement between thedriver 1300 and the belt 1330, while also providing wear resistance. Forexample, in some embodiments, a portion of the driver 1300 (e.g., theradially outer surface and/or the sprockets 1310) has a Shore D hardnessof at least about 70 and/or less than or equal to about 100. In certainembodiments, a portion of the driver 1300 has a Shore D hardness of atleast about 80 and/or less than or equal to about 90.

With reference to FIGS. 20 and 21, an embodiment of a driver 1400 isillustrated. The driver 1400 can be used to drive a belt of a modulartransfer unit such as those described herein. For example, the driver1400 can be used with a 2253RT belt (available from System Plast S.r.l.)or other belts. In some embodiments, the driver 1400 is used to drivethe primary belt 112. In some embodiments, the driver 1400 is used todrive the diverter belt 122.

The driver 1400 can include any of the features of the drivers 1200,1300. For example, the driver 1400 can include a shaft 1410 to which thedriver 1400 can be attached to a power source, such as a motor. Thedriver 1400 can include one or more recessed areas 1430 (e.g., grooves).The recessed areas 1430 can be sized to allow movable components of thebelt, such as movable components 116 described in connection with FIG.2, to pass over the driver 1400. The driver 1400 can include engagementregions 1420 between the recessed areas 1430. The engagement regions1420 can engage and/or drive the belt. As illustrated, in someembodiments, the driver 1400 does not include a sprocket.

In some implementations, the engagement regions 1420 provide analternative engagement mechanism to the sprocket. In someimplementations, the driver 1400 can include engagement regions 1420 toreduce the amount of force applied by each engagement region 1420 to thedriven belt, but to apply sufficient overall force (e.g., throughfrictional engagement) to engage with the driven belt. This canfacilitate smoother and/or quieter operation of the belt while the beltis being driven by the driver 1500 (e.g., as compared to a sprocketdriven driver under the same conditions).

With reference to FIG. 22, in some implementations of any of the modulartransfer units 100, 200, 300, 410, 520, 522, 620, 622, 624, 626, 800,900, 1010 described above, a divert system 1520 engages with a primaryflow system (not illustrated), such as the first conveyance system 110.A diverter belt 1522 can be engaged with a primary belt. For example, ata top side 1522 a of the diverter belt 1522 can engage with an undersideof the primary belt, such as with the movable components 116. Thediverter belt 1522 can be positioned on a driver 1524, which can besimilar or identical to any of the drivers described above. The driver1524 can rotate to drive the diverter belt.

As discussed above, the diverter belt and primary belt can move relativeto each other, such as at a generally perpendicular angle. In someimplementations, the primary flow belt can exert a lateral force F onthe diverter belt 1522 due to the engagement between the two belts. Thislateral force F can cause the diverter belt 1522 to move relative to theprimary flow belt and/or the driver 1524, which can be referred to as a“tracking” problem. In some embodiments, the lateral force F can causethe diverter belt 1522 to become misaligned (e.g., off-center) with thedriver 1524 in the direction of the primary flow path. For example, thediverter belt 1522 can shift in the direction of the primary flow path.Shifting of the diverter belt 1522 relative to the primary flow beltand/or the driver 1524 can cause problems with the diverter belt 1522.For example, such shifting can increase wear on the diverter belt and/orthe driver 1524, can reduce efficiency, and/or can leave portions of theprimary flow belt without adequate (or any) engagement with the diverterbelt 1522. In some embodiments, shifting of the diverter belt 1522relative to the primary flow belt and/or the driver 1524 can result inoperational errors. For example, such shifting may lead to diverter belt1522 failing to engage (e.g., rotate) certain of the movable components116, which may lead to an article conveyed on the primary flow beltbeing diverted late and/or on an incorrect path. By

In some implementations, the divert system 1520 is configured to enhancetracking of the diverter belt 1522 with the driver 1524 and/or theprimary flow belt. In some embodiments, the diverter belt 1522 caninclude tracking facilitation elements, such as first and second ribs1521, 1523. In some implementations, the first and second ribs 1521,1523 can extend the length of the diverter belt 1522. In some variants,the first and second ribs 1521, 1523 are intermittent along the lengthof the diverter belt 1522.

The driver 1524 can include corresponding tracking facilitationelements, such as first and second channels 1525, 1526. The first andsecond channels 1525, 1526 can be configured to receive the first andsecond ribs 1521, 1523, respectively. As shown in FIG. 22, a bottom side1522 b of the diverter belt 1522 engages the driver 1524 and the firstand second ribs 1521, 1523 engage within the first and second channels1525, 1526. The ribs and channels can be shaped to engage in a mannerthat produces a reactionary force R that is opposite in direction to thelateral force F. For example, the cross-sectional shapes of either orboth of the ribs and channels can be v-shaped, rectangular-shaped,arc-shaped, or any other suitable shape. In some implementations, thev-shaped ribs and channels can automatically realign the diverter belt1522 with the driver 1524 in response to a slight misalignment (e.g.,due to the lateral force F). In some implementations, a tip of thev-shaped rib is maintained within the corresponding channel andfacilitates realignment of the diverter belt 1522 and the driver 1524.

The first and second ribs 1521, 1523 and channel can be located onopposite ends of the driver 1524. The first rib 1521 (and channel 1525)can be spaced a distance S1 from a first lateral side 1527 of thediverter belt 1522. The second rib 1523 (and channel 1526) can be spaceda distance S2 from a second lateral side 1528 of the diverter belt 1522.A width S3 can separate the first and second lateral sides 1527, 1528.In some implementations, the ratio of S1 and/or S2 to the width S3 canbe between 1/10 and 1/3. In some implementations S1 and S2 can besubstantially equivalent.

Certain Frame Embodiments

As mentioned above, in some embodiments, the modular transfer unit 100can include a frame 130 that can be used to support one or morecomponents of the modular transfer unit 100. In some embodiments, theframe 130 supports both the primary flow belt 112 and the diverter belt122. In some embodiments, the modular transfer unit 100 does not have aframe 130 that supports both the primary flow belt 112 and the diverterbelt 122. For example, the diverter belt 122 can be supported separatelyfrom the primary flow belt 112. Having separate support structures forthe primary flow and the diverter belts can facilitate installation,removal, and/or maintenance. As shown in FIGS. 23A and 23B, a diverterbelt unit 1600 can include the diverter belt 122 and a support structure1602. The support structure 1602 can include a bracket. As illustrated,in some variants, the support structure 1602 can support a bottomportion of the diverter belt 122, which can reduce sag in the bottomportion of the diverter belt 122. For example, the support structure1602 can include rails on which a return portion of the diverter belt122 is supported and/or slides. The support structure 1602 can beconnected to support elements, such as legs (not shown).

The primary flow belt 112 can have a support configuration that issimilar or identical to what is described above in connection with thediverter belt 122. For example, a primary flow belt unit can include theprimary flow belt 112 and a support structure 1602 that engages withsupport elements, such as legs. In some embodiments, the supportstructures of the primary flow belt unit and the diverter belt unitengage with the same legs. In some embodiments, the support structuresof the primary flow belt unit engage with a first set of legs and thesupport structures of the diverter belt unit engage with a second set oflegs.

Certain Transfer Modules

Some embodiments include features to facilitate conveying goods betweenconveyor belts, such as between adjacent primary flow belts 112. Forexample, as shown in FIG. 25, a transfer module 1700 can be positionedin a gap between longitudinally adjacent primary flow belts 112. Goodsexiting a first (e.g., upstream) belt can pass along the transfer moduleto smoothly enter a second (e.g., downstream) belt. In variousembodiments, the transfer module 1700 extends substantially from onelateral side of at least one of the primary flow belts 112 to anotherlateral side of at least one of the primary flow belts 112. As shown,the transfer module 1700 can include concave sides, which can enable thetransfer module 1700 to receive portions of the primary flow belts 112and/or drive elements (e.g., sprockets). In some embodiments, thetransfer module 1700 includes a support 1702, such as a bracket. Incertain implementations, the support 1702 connects to the frame of themodular transfer unit 100. A top surface of the transfer module 1700 canbe generally flush with a top surface of the primary flow belts 112,such as about at the same elevation as the top of the movable components116.

In some embodiments, a sensor 1704, such as a photoelectric sensor, canbe positioned in the transfer module 1700. The sensor 1704 can beconfigured to detect goods on the transfer module 1700. A signal fromthe sensor 1704 can be sent to a control system that controls themodular transfer unit 100. In certain embodiments, the sensor 1704extends across substantially the entire lateral width of the transfermodule 1700 and/or at least one of the primary flow belts 112. In somevariants, such as is shown in FIGS. 25A and 25B, the sensor 1704 can bepositioned in a recess 1706 in the transfer module 1700. An uppersurface of the sensor 1704 can be generally flat and/or generally flushwith an upper surface of the transfer module 1700, which can aid indetecting and/or supporting goods. In certain embodiments, the transfermodule 1700 and/or the sensor 1704 are secured to a support surface(e.g., a frame of the modular transfer unit 100) with fasteners 1708,such as bolts and nuts. In some variants, a bracket 1710 is used tosecure the sensor 1704 in the transfer module 1700.

Certain Filler Elements

As shown in FIG. 26, in some embodiments, the modular transfer unit 100includes a filler element 1800, such as a filler plate. The fillerelement 1800 can be configured to contact the underside of the pluralityof movable components 116 of the primary flow belt 112. The fillerelement 1800 can be positioned in a “dead space” near the entry and/orexit of the primary flow belt 112. The dead space near the entry can bea gap in which the moving components 116 have rotated off of the driveelement (e.g., a roller or sprocket) that drives the primary flow belt112 and/or onto the top surface of the primary flow belt 112, but havenot yet moved into contact with the upstream lateral edge of thediverter belt 122. The dead space near the exit can be a gap in whichthe moving components 116 have moved past the downstream lateral edge ofthe diverter belt 122 but have not yet exited the top surface of theprimary flow belt 112 and/or engaged with the drive element. In the deadspace, the movable components 116 are on the conveying surface of theprimary flow belt 112 but are not being caused to rotate. This canreduce control of goods conveyed on the primary flow belt 112, causeunwanted speed changes of the goods, or other issues.

In various embodiments, the filler element 1800 can reduce or eliminatethe dead space. For example, the filler element 1800 can fill the gapand cause the movable components 116 to begin rotating before themovable components 116 contact the diverter belt 122. In someembodiments, the filler element 1800 causes the movable components 116to begin rotating substantially immediately after the movable components116 disengages from the drive element, such as within less than or equalto about 0.5 seconds and/or within less than or equal to about 10 mm oftravel of the primary flow belt 112.

In some implementations, the filler element 1800 can fill the gap andcause the movable components 116 to continue rotating after passinglongitudinally beyond the downstream lateral edge of the diverter belt122. In certain embodiments, the filler element 1800 causes the movablecomponents 116 to continue rotating until substantially immediatelybefore the movable components 116 engage with the drive element. Forexample, in some variants, the gap in which the movable components 116on the top of the primary flow belt 112 are not engaged (e.g., beingcaused to rotate) is less than or equal to about 0.5 seconds and/or lessthan or equal to about 10 mm of travel of the primary flow belt 112.

In various embodiments, the filler element 1800 can be positionedadjacent to and/or between the drive element and a lateral edge of thediverter belt 122. In some embodiments, the filler element 1800 caninclude concave sides, which can enable the filler element to receiveportions of the primary flow belts 112 and/or drive elements (e.g.,sprockets). In some implementations, the filler element 1800 comprises agenerally flat plate. Some embodiments have a filler element 1800 thatis positioned next to one lateral edge of the diverter belt 122, such asnext to the upstream or downstream lateral edge. Certain embodiments,such as the embodiment shown in FIG. 26, have a plurality of fillerelements 1800, such as a filler element positioned next to the upstreamand downstream lateral edges of the diverter belt. A top surface of thefiller element 1800 can be generally co-planar with and/or generallyparallel to a top surface of the diverter belt 122. In variousembodiments, the filler element 1800 is located underneath the conveyingsurface of the primary flow belt 112.

Certain Other Embodiments

While certain embodiments have been described, these embodiments havebeen presented by way of example only, and are not intended to limit thescope of the disclosure. Indeed, the novel methods and systems describedherein may be embodied in a variety of other forms. Furthermore, variousomissions, substitutions and changes in the systems and methodsdescribed herein may be made without departing from the spirit of thedisclosure. The accompanying claims and their equivalents are intendedto cover such forms or modifications as would fall within the scope ofthe disclosure. Accordingly, the scope of the present disclosure isdefined only by reference to the claims presented herein or as presentedin the future.

Features, materials, characteristics, or groups described in conjunctionwith a particular aspect, embodiment, or example are to be understood tobe applicable to any other aspect, embodiment or example described inthis section or elsewhere in this specification unless incompatibletherewith. All of the features disclosed in this specification(including any accompanying claims, abstract and drawings), and/or allof the steps of any method or process so disclosed, may be combined inany combination, except combinations where at least some of suchfeatures and/or steps are mutually exclusive. The protection is notrestricted to the details of any foregoing embodiments. The protectionextends to any novel one, or any novel combination, of the featuresdisclosed in this specification (including any accompanying claims,abstract and drawings), or to any novel one, or any novel combination,of the steps of any method or process so disclosed.

Furthermore, certain features that are described in this disclosure inthe context of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresthat are described in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations, one or more features from a claimedcombination can, in some cases, be excised from the combination, and thecombination may be claimed as a subcombination or variation of asubcombination.

For purposes of this disclosure, certain aspects, advantages, and novelfeatures are described herein. Not necessarily all such advantages maybe achieved in accordance with any particular embodiment. Thus, forexample, those skilled in the art will recognize that the disclosure maybe embodied or carried out in a manner that achieves one advantage or agroup of advantages as taught herein without necessarily achieving otheradvantages as may be taught or suggested herein.

Certain Terminology

Conditional language, such as “can,” “could,” “might,” or “may,” unlessspecifically stated otherwise, or otherwise understood within thecontext as used, is generally intended to convey that certainembodiments include, while other embodiments do not include, certainfeatures, elements, and/or steps. Thus, such conditional language is notgenerally intended to imply that features, elements, and/or steps are inany way required for one or more embodiments or that one or moreembodiments necessarily include logic for deciding, with or without userinput or prompting, whether these features, elements, and/or steps areincluded or are to be performed in any particular embodiment.

Conjunctive language such as the phrase “at least one of X, Y, and Z,”unless specifically stated otherwise, is otherwise understood with thecontext as used in general to convey that an item, term, etc. may beeither X, Y, or Z. Thus, such conjunctive language is not generallyintended to imply that certain embodiments require the presence of atleast one of X, at least one of Y, and at least one of Z.

Terms relating to circular shapes as used herein, such as diameter orradius, should be understood not to require perfect circular structures,but rather should be applied to any suitable structure with across-sectional region that can be measured from side-to-side. Termsrelating to shapes generally, such as “spherical” or “circular” or“cylindrical” or “semi-circular” or “semi-cylindrical” or any related orsimilar terms, are not required to conform strictly to the mathematicaldefinitions of spheres, circles, cylinders or other structures, but canencompass structures that are reasonably close approximations.

The terms “approximately,” “about,” and “substantially” as used hereinrepresent an amount close to the stated amount that still performs adesired function or achieves a desired result. For example, in someembodiments, as the context may permit, the terms “approximately”,“about”, and “substantially” may refer to an amount that is within lessthan or equal to 10% of the stated amount. The term “generally” as usedherein represents a value, amount, or characteristic that predominantlyincludes or tends toward a particular value, amount, or characteristic.As an example, in certain embodiments, as the context may permit, theterm “generally parallel” can refer to something that departs fromexactly parallel by less than or equal to 20 degrees. As anotherexample, in certain embodiments, as the context may permit, the term“generally perpendicular” can refer to something that departs fromexactly perpendicular by less than or equal to 20 degrees.

The terms “comprising,” “including,” “having,” and the like aresynonymous and are used inclusively, in an open-ended fashion, and donot exclude additional elements, features, acts, operations, and soforth. Likewise, the terms “some,” “certain,” and the like aresynonymous and are used in an open-ended fashion. Also, the term “or” isused in its inclusive sense (and not in its exclusive sense) so thatwhen used, for example, to connect a list of elements, the term “or”means one, some, or all of the elements in the list.

Overall, the language of the claims is to be interpreted broadly basedon the language employed in the claims. The language of the claims isnot to be limited to the non-exclusive embodiments and examples that areillustrated and described in this disclosure, or that are discussedduring the prosecution of the application.

SUMMARY

Although the modular transfer system has been disclosed in the contextof certain embodiments and examples, it will be understood by thoseskilled in the art that this disclosure extends beyond the specificallydisclosed embodiments to other alternative embodiments and/or uses ofthe embodiments and certain modifications and equivalents thereof. Thescope of the present disclosure is not intended to be limited by thespecific disclosures of preferred embodiments in this section orelsewhere in this specification, and may be defined by claims aspresented in this section or elsewhere in this specification or aspresented in the future. The language of the claims is to be interpretedbroadly based on the language employed in the claims and not limited tothe examples described in the present specification or during theprosecution of the application, which examples are to be construed asnon-exclusive.

The following is claimed:
 1. A modular transfer system comprising: amain belt comprising a plurality of hingedly-connected belt modules,each of the plurality of belt modules comprising a body and a pluralityof spherical balls, the spherical balls having an upper portion thatprotrudes above an upper surface of the body and a lower portion thatprotrudes below a lower surface of the body, the spherical ballsconfigured to rotate relative to the body, the main belt configured totravel in a first direction; a plurality of diverter belts engaged withthe main belt, each of the diverter belts being operable independent ofthe other diverter belts, wherein the plurality of diverter beltscomprises a diverter belt configured to travel in a second directionthat is generally perpendicular to the first direction, the diverterbelt in contact with the protruding lower portion of the spherical ballssuch that relative movement of the main and diverter belt causes thespherical balls to rotate; and a main belt drive unit configured todrive the main belt in the first direction, the main belt drive unitcomprising a motor and a motorized drive roller, the motorized driveroller comprising: a radially outer surface that is configured to engagewith the lower surface of the body of the main belt to provide drivingforce on the main belt; a plurality of grooves in the radially outersurface, the grooves extending radially inwardly and configured toreceive the protruding lower portion of the spherical balls; and asprocket configured to engage into a recess in the body of the beltmodules of the main belt to provide additional driving force on the mainbelt.
 2. The modular transfer system of claim 1, wherein the sphericalballs are free to rotate with three rotational degrees of freedom. 3.The modular transfer system of claim 1, wherein the motorized driverroller comprises a plurality of sprockets.
 4. The modular transfersystem of claim 1, wherein the diverter belt comprises a first v-shapedrib and a second v-shaped rib, the first and second ribs being spacedsubstantially equally between lateral sides of the diverter belt.
 5. Themodular transfer system of claim 1, further comprising a diverter beltdrive unit configured to drive the diverter belt in the seconddirection, the diverter belt drive unit comprising a motor and asprocket.
 6. The modular transfer system of claim 1, wherein thediverter belt is maintained in constant contact with the protrudinglower portion of at least one of the spherical balls.
 7. The modulartransfer system of claim 1, further comprising a control systemconfigured to: detect that an article moving in the first direction isat a divert zone of the modular transfer system; determine that thearticle is to be diverted towards a side of the modular transfer system;and operate the diverter belt to cause the article to change from movingin the first direction to moving toward the side of the modular transfersystem.
 8. A modular transfer system comprising: a main belt comprisinga plurality of spherical balls, the main belt configured to convey anarticle along a primary flow path; a plurality of diverter beltspositioned under and engaged with the main belt, each of the pluralityof diverter belts comprising first and second ribs, the plurality ofdiverter belts comprising a diverter belt positioned under the mainbelt, the diverter belt oriented generally perpendicular to the primaryflow path, an upper surface of the diverter belt contacting a bottom ofthe plurality of the spherical balls of the main belt, an under surfaceof the diverter belt comprising the first rib on a first side of acenterline of the diverter belt and the second rib on a second side ofthe centerline of the diverter belt; and a drive roller engaged with thediverter belt, the drive roller configured to drive the diverter belt tocause the spherical balls of the main belt to rotate with a component ofmotion toward a side of the main belt, thereby diverting an article onthe main belt from the primary flow path, wherein the drive rollercomprises: a first channel configured to receive the first rib of thediverter belt; and a second channel configured to receive the second ribof the diverter belt; and wherein the respective engagement between thefirst and second ribs of the diverter belt and the first and secondchannels reduces misalignment of the diverter belt relative to the mainbelt.
 9. The modular transfer system of claim 8, wherein the first andsecond ribs of the diverter belt are v-shaped and the first and secondchannels are correspondingly v-shaped.
 10. The modular transfer systemof claim 8, wherein the first and second ribs of the diverter belt aredisposed inwardly from respective lateral sides of the diverter belt byapproximately the same distance.
 11. The modular transfer system ofclaim 8, wherein the first and second ribs of the diverter belt arespaced to divide a width of the diverter belt into three sections ofsubstantially equivalent width.
 12. The modular transfer system of claim8, wherein at least two of the plurality of diverter belts move atdifferent speeds.
 13. A modular transfer system comprising: a primaryflow system comprising a primary flow belt, the primary flow beltconfigured to convey an article along a primary direction of travel, theprimary flow belt being a modular conveyor belt comprising a firstlateral side, a second lateral side, and a plurality of balls havingthree rotational degrees of freedom; a diverter system comprising: afirst diverter belt configured to divert an article from the primarydirection of travel, the first diverter belt contacting an underside ofthe plurality of balls in a first section of the primary flow belt, thefirst section extending from the first lateral side of the primary flowbelt to the second lateral side of the primary flow belt; a firstmotorized roller unit configured to drive the first diverter belt; asecond diverter belt configured to further divert the article from theprimary direction of travel, the second diverter belt contacting anunderside of the plurality of balls in a second section of the primaryflow belt, the second section being adjacent to the first section in theprimary direction of travel and extending from the first lateral side ofthe primary flow belt to the second lateral side of the primary flowbelt; and a second motorized roller unit configured to drive the seconddiverter belt; and a control system configured to operate the firstmotorized roller unit and the second motorized roller unitindependently, thereby diverting articles in the first sectionindependent of articles in the second section.
 14. The modular transfersystem of claim 13, wherein the first and second diverter belts disposedsubstantially perpendicularly with the primary flow belt.
 15. Themodular transfer system of claim 13, wherein the first and seconddiverter belts each comprise a plurality of v-shaped ribs.
 16. Themodular transfer system of claim 13, further comprising a motorizeddrive roller engaged with the primary flow belt to operate the primaryflow belt, the motorized drive roller including a plurality of sprocketsto engage the primary flow belt and a plurality of grooves toaccommodate the plurality of balls.
 17. The modular transfer system ofclaim 13, wherein the control system is further configured to: detectthat an article moving in the primary direction of travel is at a divertzone of the modular transfer system; determine that the article is to bediverted towards a side of the modular transfer system; and operate thediverter system to cause the article to change from moving in theprimary direction of travel to moving toward the side of the modulartransfer system.
 18. The modular transfer system of claim 17, whereinthe control system is further configured to operate the first and seconddiverter belts in response to determining that an article is to bediverted or to be passed through the modular transfer unit, the firstdiverter belt operating at a first speed in a divert direction and thesecond diverter belt operating at a second speed in the divertdirection.
 19. The modular transfer system of claim 17, wherein thecontrol system is configured to determine whether an article is at thedivert zone based on a signal received from a sensor.
 20. The modulartransfer system of claim 19, wherein the control system is configured todetermine whether an article is at the divert zone based on a time delayafter receiving the signal from the sensor, the sensor being positionedat a location before the divert zone in the primary direction of travel.21. The modular transfer system of claim 13, further comprising a fillerelement longitudinally positioned between a drive element that drivesthe primary flow belt and a lateral edge of the first diverter belt, thefiller element configured to contact the underside of the plurality ofballs before the balls contact the first diverter belt, thereby causingthe balls to rotate before reaching the first diverter belt.
 22. Amodular transfer system comprising: a main belt comprising a pluralityof spherical balls, the main belt configured to convey an article alonga primary flow path; a plurality of diverter belts, wherein at least twoof the plurality of diverter belts move at different speeds, theplurality of diverter belts comprising a diverter belt positioned underthe main belt, the diverter belt oriented generally perpendicular to theprimary flow path, an upper surface of the diverter belt contacting abottom of the plurality of the spherical balls of the main belt, anunder surface of the diverter belt comprising a first rib on a firstside of a centerline of the diverter belt and a second rib on a secondside of the centerline of the diverter belt; and a drive roller engagedwith the diverter belt, the drive roller configured to drive thediverter belt to cause the spherical balls of the main belt to rotatewith a component of motion toward a side of the main belt, therebydiverting an article on the main belt from the primary flow path,wherein the drive roller comprises: a first channel configured toreceive the first rib of the diverter belt; and a second channelconfigured to receive the second rib of the diverter belt; and whereinthe respective engagement between the first and second ribs and thefirst and second channels reduces misalignment of the diverter beltrelative to the main belt.
 23. The modular transfer system of claim 22,wherein the first and second ribs are v-shaped and the first and secondchannels are correspondingly v-shaped.
 24. The modular transfer systemof claim 22, wherein the first and second ribs are disposed inwardlyfrom respective lateral sides of the diverter belt by approximately thesame distance.
 25. The modular transfer system of claim 22, wherein thefirst and second ribs are spaced to divide a width of the diverter beltinto three sections of substantially equivalent width.